Removal and Replacement

Piston and Connecting Rod

Special tools, testers and auxiliary items required

• Guide Pins (8189)

Removing

• Refer to the connecting rod description before beginning repair. Refer to => [ Piston and Connecting Rod ] Description and Operation.

- Disconnect the negative battery cable.

- Remove the cylinder heads. Refer to => [ Cylinder Head ] Cylinder Head.

- Remove the oil pan. Refer to => [ Oil Pan ] Removal and Replacement.

- Remove the top ridge of cylinder bores with a reliable ridge reamer, if necessary before removing the pistons from the cylinder block. Be sure to keep the tops of the pistons covered during this operation. Pistons and connecting rods must be removed from the top of cylinder block. When removing the piston and connecting rod assemblies from the engine, rotate the crankshaft so that each connecting rod is centered in the cylinder bore.

- Inspect the connecting rods and connecting rod caps for cylinder identification (1). Identify them (1), if necessary.






- Remove the connecting rod cap. Install the guide pins (8189) (3) onto the connecting rod (4).






- Remove the piston (1) and connecting rod (4) out of the cylinder bore.

• Be careful not to nick the crankshaft journals.

- After removal, Install the bearing cap on the mating rod.

Installing

- Before installing the piston and connecting rod into the bore, ensure that the compression ring gaps (2 and 5) are staggered so that neither is in line with the oil ring gaps (1 and 4).






- Lubricate the piston (1) and rings with clean engine oil. Position a ring compressor (2) over the piston (1) and rings, and tighten the compressor (2). Be sure the position of the rings does not change during this operation.






- Position the upper bearing onto the connecting rod. Lubricate the bearing with oil.

- Install the guide pins (8189) (3) onto the connecting rod (4).

- The pistons are marked with an arrow (1) on top of the piston. Install the piston with this mark positioned to the front of the engine on both cylinder banks. The connecting rod oil squirt hole faces the major thrust (right) side of the engine block.






- Rotate the crankshaft until the connecting rod journal is located in the center of the cylinder bore. Insert the connecting rod (4) and piston (1) into the cylinder bore by tapping down on the piston (1) using a hammer handle. At the same time, guide the connecting rod (4) into position on the connecting rod journal.






- Install the lower bearing shell and the appropriate connecting rod cap.

- Install the connecting rod cap bolts following this three step torque plus angle method:

• Step 1: Tighten both bolts to 7 Nm (5 ft. lbs).

• Step 2: Tighten both bolts to 28 Nm (21 ft. lbs).

• Step 3: Tighten both bolts an additional 90°.

- Repeat tightening procedure for each piston and connecting rod installed.

- Install the cylinder heads. Refer to => [ Cylinder Head ] Cylinder Head.

- Install the oil pan. Refer to => [ Oil Pan ] Removal and Replacement.

- Fill the engine crankcase with the proper oil and to the correct level.

- Connect the negative battery cable.